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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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Energy Conversion Alternatives Study (ECAS), Westinghouse phase 1. Volume 2: Materials considerations

Extensive studies are presented which were carried out on materials behavior in nine advanced energy conversion systems employing coal and coal-derived fuels. The areas of materials behavior receiving particular attention in this regard are: (1) fireside corrosion and erosion in boiler and heat exchanger materials, (2) oxidation and hot corrosion of gas turbine materials, (3) liquid metal corrosion and mass transport, (4) high temperature steam corrosion, (5) compatability of materials with coal slag and MHD seed, (6) reaction of materials with impure helium, (7) allowable stresses for boiler and heat exchanger materials, (8) environmental effects on mechanical properties, and (9) liquid metal purity control and instrumentation. Such information was then utilized in recommending materials for use in the critical components of the power systems, and at the same time to identify materials problem areas and to evaluate qualitatively the difficulty of solving those problems. Specific materials recommendations for critical components of the nine advanced systems under study are contained in summary tables.

Thomas, D. E.↗

Critical research and advanced technology (CRT) support project

A critical technology base for utility and industrial gas turbines by planning the use of coal-derived fuels was studied. Development tasks were included in the following areas: (1) Combustion - investigate the combustion of coal-derived fuels and methods to minimize the conversion of fuel-bound nitrogen to NOx; (2) materials - understand and minimize hot corrosion; (3) system studies - integrate and focus the technological efforts. A literature survey of coal-derived fuels was completed and a NOx emissions model was developed. Flametube tests of a two-stage (rich-lean) combustor defined optimum equivalence ratios for minimizing NOx emissions. Sector combustor tests demonstrated variable air control to optimize equivalence ratios over a wide load range and steam cooling of the primary zone liner. The catalytic combustion of coal-derived fuels was demonstrated. The combustion of coal-derived gases is very promising. A hot-corrosion life prediction model was formulated and verified with laboratory testing of doped fuels. Fuel additives to control sulfur corrosion were studied. The intermittent application of barium proved effective. Advanced thermal barrier coatings were developed and tested. Coating failure modes were identified and new material formulations and fabrication parameters were specified. System studies in support of the thermal barrier coating development were accomplished.

Furman, E. R.↗

Gas turbine critical research and advanced technology (CRT) support project

The technical progress to provide a critical technology base for utility gas turbine systems capable of burning coal-derived fuels is summarized. Project tasks include the following: (1) combustion - to investigate the combustion of coal-derived fuels and the conversion of fuel-bound nitrogen to NOx; (2) materials - to understand and prevent the hot corrosion of turbine hot section materials; and (3) system studies - to integrate and guide the technological efforts. Technical accomplishments include: an extension of flame tube combustion testing of propane - Toluene Fuel Mixtures to vary H2 content from 9 to 18 percent by weight and the comparison of results with that predicted from a NASA Lewis General Chemical Kinetics Computer Code; the design and fabrication of combustor sector test section to test current and advanced combustor concepts; Testing of Catalytic combustors with residual and coal-derived liquid fuels; testing of high strength super alloys to evaluate their resistance to potential fuel impurities using doped clean fuels and coal-derived liquids; and the testing and evaluation of thermal barrier coatings and bond coatings on conventional turbine materials.

Furman, E. R.↗

Gas-turbine critical research and advanced technology support project

The technical progress made during the first 15 months of a planned 40-month project to provide a critical-technology data base for utility gas-turbine systems capable of burning coal-derived fuels is summarized. Tasks were included in the following areas: (1) combustion, to study the combustion of coal-derived fuels and conversion of fuel-bound nitrogen to NOx; (2) materials, to understand and prevent hot corrosion; and (3) system studies, to integrate and guide the other technologies. Significant progress was made.

Clark, J. S.↗

Status of the DOE/NASA critical gas turbine research and technology project

Activities performed in order to provide an R&T data base for utility gas turbine systems burning coal-derived fuels are described. Experiments were run to determine the corrosivity effects of trace metal contaminants (and potential fuel additives) on gas turbine materials and these results were correlated in a corrosion-life prediction model. Actual fuels were burned in a burner rig hot corrosion test to verify the model. A deposition prediction model was assembled and compared with results of actual coal-derived fuel deposition tests. Thermal barrier coatings were tested to determine their potential for protecting gas turbine hardware from the corrosive contaminants. Several coatings were identified with significantly improved spallation-resistance (and, hence, corrosion resistance).

Clark, J. S.↗

Status of the DOE/NASA critical gas turbine R & T Project

The purpose of the DOE/NASA CRT (Critical Research and Technology) Project at the Lewis Research Center is to provide an R&T data base for utility gas turbine systems burning coal-derived fuels. Coal-derived fuels present difficult problems in combustion (because of the high organically-bound nitrogen in the fuel), and materials (because of the trace metal contaminant levels in the fuels, leading to corrosion and deposition in the turbine hot section). The combustion task includes (1) an effort to model the rich-lean combustion process, to predict NOx emissions; (2) a two-stage flame tube experiment to study the effects of combustion operating conditions and fuel properties on NOx conversion; and (3) scaled combustor tests to evaluate the NOx-reduction potential of several staged-combustion concepts. The materials-corrosion resistance effort attacks the problem on three sides.

Clark, J. S.↗

Evaluation of concepts for controlling exhaust emissions from minimally processed petroleum and synthetic fuels

Rich-lean combustor concepts designed to enhance rich combustion chemistry and increase combustor flexibility for NO(x) reduction with minimally processed fuels are examined. Processes such as rich product recirculation in the rich chamber, rich-lean annihilation, and graduated air addition or staged rich combustion to release bound nitrogen in steps of reduced equivalence ratio are discussed. Variations to the baseline rapid quench section are considered, and the effect of residence time in the rich zone is investigated. The feasibility of using uncooled non-metallic materials for the rich zone combustion construction is also addressed. The preliminary results indicate that rich primary zone staged combustion provides environmentally acceptable operation with residual and/or synthetic coal-derived liquid fuels

Russell, P. L.↗

Comparative Evaluation of Phase 1 Results from the Energy Conversion Alternatives Study (ECAS)

Ten advanced energy conversion systems for central-station, based-load electric power generation using coal and coal-derived fuels which were studied by NASA are presented. Various contractors were selected by competitive bidding to study these systems. A comparative evaluation is provided of the contractor results on both a system-by-system and an overall basis. Ground rules specified by NASA, such as coal specifications, fuel costs, labor costs, method of cost comparison, escalation and interest during construction, fixed charges, emission standards, and environmental conditions, are presented. Each system discussion includes the potential advantages of the system, the scope of each contractor's analysis, typical schematics of systems, comparison of cost of electricity and efficiency for each contractor, identification and reconciliation of differences, identification of future improvements, and discussion of outside comments. Considerations common to all systems, such as materials and furnaces, are also discussed. Results of selected in-house analyses are presented, in addition to contractor data. The results for all systems are then compared.

Source record↗

Advanced air transport concepts

The concepts of laminar flow control, very large all-wing aircraft, an aerial relay transportation system and alternative fuels, which would enable large improvements in fuel conservation in air transportation in the 1990's are discussed. Laminar boundary layer control through suction would greatly reduce skin friction and has been reported to reduce fuel consumption by up to 29%. Distributed load aircraft, in which all fuel and payload are carried in the wing and the fuselage is absent, permit the use of lighter construction materials and the elimination of fuselage and tail drag. Spanloader aircraft with laminar flow control could be used in an aerial relay transportation system which would employ a network of continuously flying liners supplied with fuel, cargo and crews by smaller feeder aircraft. Liquid hydrogen and methane fuels derived from coal are shown to be more weight efficient and less costly than coal-derived synthetic jet fuels.

Molloy, J. K.↗